U.S. patent number 7,574,896 [Application Number 11/604,636] was granted by the patent office on 2009-08-18 for leak detection and control.
This patent grant is currently assigned to Michigan Aqua Tech, Inc.. Invention is credited to Ralph W. Cooper.
United States Patent |
7,574,896 |
Cooper |
August 18, 2009 |
Leak detection and control
Abstract
Fluid leaks can be detected and controlled in a pressurized
piping system. Apparatus for this includes control logic; in
communication with the logic, a flow detector and/or a pressure
detector, and a control valve. One or more of the following is or
are provided also: the flow and pressure detectors are both
present, and both as single units; the control logic, the flow
and/or pressure detector(s) and the control valve are in close
proximity to one another; and the control valve has a baseline
condition of being shut off. A remote control device can remotely
interact with the control logic. Pressure decay and/or flow
properties can be employed. The fluid can be water as, for example,
in a residential, commercial or institutional system.
Inventors: |
Cooper; Ralph W. (Sanford,
MI) |
Assignee: |
Michigan Aqua Tech, Inc.
(Sanford, MI)
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Family
ID: |
40942558 |
Appl.
No.: |
11/604,636 |
Filed: |
November 27, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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10665921 |
Feb 13, 2007 |
7174771 |
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Current U.S.
Class: |
73/40.5R |
Current CPC
Class: |
G01M
3/2815 (20130101) |
Current International
Class: |
G01M
3/28 (20060101) |
Field of
Search: |
;73/40,40.5R ;137/15.11
;340/605 ;702/51 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
US. Appl. No. 10/665,921, Cooper. cited by other .
Aqua Managers, Inc., FloodStop (FS 3/8-C) unit info., Home/Product
page (www.aquamanagers.com) downloaded Nov. 27, 2006. cited by
other .
Davis inotek(R) Instruments, PSR Series Paddle Type Flow Switch
info., copyright 2004, downloaded sub-sequently (Davis.com). cited
by other .
FloLogic, Inc., The FloLogic Automatic Water Shutoff System unit
info., Home page (www.flologic.com). downloaded Nov. 27, 2006
(copyright 2006),.. with FloLogic System 3.0 Printable Spec sheet.
cited by other .
Give Systems, Inc., Aqua-Stop? water leak detection system,
executive summary downloaded (www.building.org) Nov. 27, 2006.
cited by other .
H2Control, Mitigatoor water control system, product info., home
page . . . (www.themitigator.com) with "about" info., downloaded
Nov. 27, 2006. cited by other .
DynaQuip Controls, WaterCop automatic water shut-off systems, home
page, product overview (how does it work? and where do I place
sensors?), and FAQs (www.watercop.com) downloaded Nov. 27, 2006
copyright 2006). cited by other.
|
Primary Examiner: Fitzgerald; John
Attorney, Agent or Firm: Rudy; Christopher John
Parent Case Text
This is a continuation-in-part of U.S. patent application Ser. No.
10/665,921 filed on Sep. 18, 2003 A.D., which published as Pub. No.
US 2005/0072214 A1 on Apr. 7, 2005 A.D., and which issued as U.S.
Pat. No. 7,174,771 B2 on Feb. 13, 2007 A.D. The entire
specifications to include drawings of that regular utility patent
application and that patent application publication are
incorporated herein by reference.
Claims
What is claimed is:
1. A leak detection apparatus for detecting and controlling a leak
in a pressurized piping system, which comprises: control logic;
both of one and only one flow detector in communication with said
logic, and one and only one pressure detector in communication with
said logic; and a control valve in communication with said logic;
wherein at least one of the following additional features is also
provided: the control logic, both of one and only one flow detector
and one and only one pressure detector, and the control valve are
in close proximity to one another; and the control valve has a
baseline condition of being shut off.
2. The apparatus of claim 1, wherein a remote control device is
provided, which can remotely interact with the control logic, and
allows for remote reset and override capability as well as a leak
test on demand at any time from a remote or proximate location to
insure proper operation.
3. The apparatus of claim 1, wherein the additional feature of the
control valve having a baseline condition of being shut off is
present.
4. The apparatus of claim 3, wherein a remote control device is
provided, which can remotely interact with the control logic.
5. In combination, the apparatus of claim 3 and a pressurizable
piping system to which the apparatus is connected in fluid
communication with the system for delivery of the fluid.
6. The combination of claim 5, wherein the fluid is water; the
piping system is brachiated; and a single apparatus is
connected.
7. The apparatus of claim 1, wherein the additional feature is
present of the control logic, both of one and only one flow
detector and one and only one pressure detector, and the control
valve being in close proximity to one another.
8. The apparatus of claim 7, wherein a remote control device is
provided, which can remotely interact with the control logic.
9. In combination, the apparatus of claim 7 and a pressurizable
piping system to which the apparatus is connected in fluid
communication with the system for delivery of the fluid.
10. The combination of claim 9, wherein the fluid is water; the
piping system is brachiated; and a single apparatus is
connected.
11. The apparatus of claim 1, wherein both additional features of
the control logic, both of one and only one flow detector and one
and only one pressure detector, and the control valve being in
close proximity to one another; and the control valve having a
baseline condition of being shut off are present; and wherein the
apparatus can generally discriminate between controlled and
uncontrolled pressure decay at very low flow rates.
12. The apparatus of claim 11, wherein a remote control device is
provided, which can remotely interact with the with the control
logic.
13. In combination, the apparatus of claim 11 and a pressurizable
piping system to which the apparatus is connected in fluid
communication with the system for delivery of the fluid.
14. The combination of claim 13, wherein the fluid is water; the
piping system is brachiated: a single apparatus is connected; and
the controlled pressure decay at very low flow rates is represented
by replenishment in a refrigerator's ice maker, and the
uncontrolled pressure decay at very low flow rates is represented
by an unwanted leak.
15. In combination, the apparatus of claim 1 and a pressurizable
piping system to which the apparatus is connected in fluid
communication with the system for delivery of the fluid.
16. The combination of claim 15, wherein the fluid is water; the
piping system is brachiated; and a single apparatus is
connected.
17. A leak detection apparatus for detecting and controlling a leak
in a pressurized piping system for water, which comprises, in close
proximity to one another the following: control logic; both of: one
and only one flow detector in communication with the control logic,
which can be set to detect minimal water flow; and one and only one
pressure detector in communication with the control logic, which
can be monitored in a pressure decay test initiated by the control
logic; and a control valve in communication with the control logic,
which has a baseline condition of being off.
18. The apparatus of claim 17, which further comprises the
following features: a user demand set to establish a maximum user
demand time period; a fault indicator, which can be activated
through signals from the control logic whenever a demand flow has
exceeded a preset value or when a low rate count exceeds a set
value to indicate why the apparatus has stopped flow of the water;
a leak-detected indicator, which is activated when a leak test has
failed or when a low rate count exceeds a set value to indicate why
the apparatus has stopped flow of the water; a reset to restart the
apparatus after shut down; a power-on indicator to indicate main
control power on; a demand indicator, which is activated when the
water is flowing; and a leak-testing indicator, which is activated
while a leak test is being conducted.
19. The apparatus of claim 18, which further comprises the
following: a control panel or box, which contains the following:
the control logic, said both flow detector and pressure detector,
and said control valve; and manual valves, as follows: a first
valve, which is normally closed during operation, but can be opened
for by-pass mode; and second and third valves, which are mounted on
test line sections of the apparatus; and a remote control; and
wherein: the user demand set includes a dial; the fault indicator,
the leak-detected indicator, the power-on indicator, the demand
indicator, and the leak-testing indicator include lights; and the
reset includes a button.
20. The apparatus of claim 17, which further comprises the
following: A. User inputs associated with the control logic, which
include the following inputs controllable from a panel front: a
system reset button; and a flow guard knob, which is a variable
resistor type with control in minutes; and a wireless remote, which
also can provide for user input; B. User monitoring outputs located
on the panel front and associated with the control logic, which
include the following: a power-on lamp; a flow guard lamp; a flow
fault lamp; a leak guard lamp; and a leak fault lamp; and user
monitoring outputs located on the remote; C. Standard inputs with
respect to terminal strip wiring associated with a control box and
the control logic, which include the following: for power, 120-V
AC, from a cord; for the flow detector, a flow switch with normally
open contact, which closes contact at approximately 0.21 gpm on
increasing flow; and for the pressure detector, a pressure switch
with normally closed contact, which opens contacts at approximately
a 30-psig value on increasing pressure; D. Standard output with
respect to terminal strip wiring associated with the control box
and control logic, which includes that to the control valve, 120-V
AC 60-Hz, normally closed, full port; E. Auxiliary inputs with
respect to optional terminal strip wiring associated with the
control box and control logic, which include the following: an
external reset switch, which allows the user to reset a fault
condition from a hardwired switch away from the control panel, and
which has normally open contact with multiple switches able to be
wired in parallel; and a flow guard override switch, which can
indicate that a long-demand item needs water, normally open contact
input; F. Auxiliary outputs with respect to optional terminal strip
wiring associated with the control box and control logic, which
include the following: a fault lamp, a security system link
normally open, closed on fault, which requires power be supplied to
the apparatus for operation; a power lamp, 5-V DC, which is for
service; and a ground for shielding; G. Non-stored configuration
settings with respect to terminal strip wiring associated with the
control box and control logic, which include that from a flow guard
timer set by the flow guard knob, which is maximum continuous time
that water can run, except when a flow guard override signal has
been received, which is a user-adjustable factor; H. Stored
configuration settings, electrically erasable permanent read only
memory (EEPROM), with respect to terminal strip wiring, associated
with the control box and control logic, which include the
following: a leak test cycle timer, which times intervals between
leak tests, and which can be programmably adjustable from the
remote to a 1-minute to 100-minute value; a leak test decay timer,
which times duration of the leak test, and which can be
programmably adjustable from the remote to a 1-minute to 100-minute
value; a flow guard override timer, which is an auxiliary input
that times maximum duration water can run when the flow guard timer
is being overridden, and which can be programmably adjustable from
the remote to a 1-hour to 10-hour value; a surge flow timer, which
can time minimum time allowed to establish a flow signal, which is
the time allowed to establish a verified flow where a flow signal
pulse from the flow switch is expected when the piping system
repressurizes and for which the flow switch remains activated for
the adjustable time period in order for a logical one-flow signal
to be generated, and which can be programmably adjustable from the
remote to a 1-second to 10-second value; a surge window timer,
which controls time allowed for flow verification, which is maximum
time allowed for a verified flow signal to be established and begin
the next programmable step, and which can be programmably
adjustable from the remote to a 1-second to 10-second value; a low
flow rate timer, which determines possible low flow represented by
drip-watering of plants or making ice in a freezer versus a leak,
which is a time window beginning a leak test when a low pressure
condition is considered a low flow instead of a leak, and which can
be programmably adjustable from the remote to a 1-second to
20-second value; and a configuration timer, which is for limiting
time allotted to complete programming of the apparatus; I. Limits
associated with the control logic, which include the following: a
leak failure limit, which is the number of leak test failures that
it takes for the apparatus to go to a leak fault status indicated
by the leak fault lamp, and which can be programmably adjustable
from the remote to a 1-count to 10-count value; and a low flow
failure limit, which is the number of low flow failures that it
takes for the apparatus to go to a flow fault status indicated by
the flow fault lamp, and which can be programmably adjustable from
the remote to a 1-count to 10-count value.
21. The apparatus of claim 20 having a further feature, which
includes a last known state program that, upon reset or restarting
of the apparatus, returns the control logic to the last step at
which it had been functioning previously, in which the state is
updated in EEPROM when a fault occurs or is cleared.
Description
FIELD AND PURVIEW OF THE INVENTION
In general, the present invention concerns detection and control of
leaks in pressurized liquid piping systems, with apparatus and
method of its employment. More particularly, the invention concerns
a leak detection apparatus and method, in which pressure decay
and/or flow properties can be employed to ascertain whether or not
a leak is present, and, preferably, to control flow of the liquid.
In particular embodiments, devices for measuring pressure decay and
flow properties are singular in number and/or are contained within
a relatively small space, for example, in a housing, which may
contain electronic controls; and more preferably, the baseline
condition for monitoring and/or controlling the piping system is
that of being shut off. Water is a liquid for which such piping
systems often are designed.
BACKGROUND TO THE INVENTION
Leaking pipes can be a devastating problem. For example, leaks from
water pipes in residential, commercial or institutional type
buildings can cause water damage, which is cosmetic or structural
in nature; electric failures and fires; and, in freezing weather,
ice build up, which can cause structural failure. A particularly
worrisome condition, especially in those structures in which some
sort of leak control system is installed, is that in which an
electrical supply failure and leaking pipes occur simultaneously.
Then, too, leaking water pipes cause unnecessarily high bills.
Various prior art discloses devices and methods for detecting leaks
in piping systems, and then automatically shutting off the supply
to the piping system in order to minimize damage and waste that can
be caused by a leak, and so forth. See, e.g., Thompson, U.S. Pat.
No. 5,441,070. See also, U.S. Pat. Nos. 2,659,383 to Frager;
4,522,229 to Guido; 4,665,932 to Quenin; 5,076,321 to Terry;
5,161,563 to Thompson; 5,347,264 to Bjorkman; 5,539,384 to to
Fraser; 5,636,653 to Titus; 5,920,265 Johnson, Jr., et al.;
6,317,051 to Cohen; 6,339,953 to Ashworth; and 6,549,857 to Fierro
et al. Prior art approaches generally were insufficiently reliable,
unable to discriminate between controlled and uncontrolled pressure
drop at very low flow rates, or too complex or expensive to be
effectively utilized in many applications.
It would be desirable to ameliorate if not solve completely
problems in the art. It would be desirable as well to improve upon
the disclosures and approaches of the prior art.
SUMMARY OF THE INVENTION
The present invention provides, in one aspect, a leak detection
apparatus for detecting and controlling a leak in a pressurized
piping system, which comprises control logic; at least one of a
flow detector in communication with said logic, and a pressure
detector in communication with said logic; and a control valve in
communication with said logic--wherein at least one of the
following features is also provided: the flow detector and the
pressure detector are both present, with the flow detector present
as a single unit, and the pressure detector present as a single
unit; the control logic, the at least one of a flow detector and a
pressure detector, and the control valve are in close proximity to
one another; and the control valve has a baseline condition of
being shut off. The apparatus can be construed to be by itself and
suitable for application with, or to be otherwise a part of, a
system for detecting a leak in a pressurized piping system,
especially one having a main fluid supply line and a plurality of
branch fluid supply lines in communication with the main fluid
supply line. Provided also, in another aspect, is a method for
detecting a leak in a pressurized piping system, which beneficially
has the main fluid supply line and plurality of branch fluid supply
lines in communication with the main line, which can comprise
operation of an apparatus or system of the invention, but which, in
general, employs pressure decay and/or flow properties to ascertain
whether or not a leak is present, and, preferably also to control a
leak that has been detected hereby.
The invention is useful in leak detection and control.
Significantly, by the invention, the art is advanced in kind. In
more commonly and broadly encountered situations, residential,
commercial and institutional water lines can be protected against
leakage automatically and with great efficiency with embodiments of
the invention. The invention avoids complexities and uncertainties
of known devices, and is highly reliable. It can generally
discriminate between controlled and uncontrolled pressure decay at
very low flow rates, i.e., those below detection by a flow switch,
the former represented, for example, by replenishment in a
refrigerator's ice-maker, the latter, an unwanted leak. It is
cost-efficient to manufacture, install, and operate. Also, the
three-valve manifold allows easy service and by-pass in the event
water is desired for delivery during a power failure. In addition,
a remote control device allows for remote reset and override
capability, among other things, and the remote control device
allows for a leak test on demand at any time, from a remote or
proximate location, to insure proper operation.
Numerous further advantages attend the invention.
DRAWINGS OF SOME INVENTION EMBODIMENTS
The drawings form part of the specification hereof. With respect to
the drawings, which are not necessarily drawn to scale, the
following is briefly noted:
FIG. 1 shows an embodiment of a leak detection apparatus or system
of the invention. Note, the parent application.
FIG. 2 shows a flow chart that illustrates an example of a method
of the invention. Note, the parent application.
FIG. 3 shows a front view of another embodiment hereof.
FIG. 4 shows a plan view of the embodiment of FIG. 3, with its
front cover removed.
FIG. 5 shows a circuit diagram for control logic in a control panel
within the embodiment of FIGS. 3 and 4.
FIG. 6 shows a remote control device that can be employed in
conjunction with apparatus of the invention, especially an
embodiment such as that of FIGS. 3-5, with a plan of its
interaction with that apparatus via its control panel (CP-1).
FIG. 7 shows a flow chart illustrating operation of the invention
with the apparatus and device of FIGS. 3-6.
FIG. 8 shows a sample pressure decay rate range of adjustment.
ILLUSTRATIVE EMBODIMENTS OF THE INVENTION
The invention can be further understood by the detail set out
below, which may be read in view of the drawings. Such is to be
taken in an illustrative and not necessarily limiting sense.
The invention provides leak detection with control of the leak in a
pressurized piping system. The piping system generally contains or
is designed to contain a fluid, typically a liquid, which is
noncompressible or nearly so, for example, water. Other fluids,
however, can be of concern, especially substantially or essentially
noncompressible liquids. The piping system can be simple, or it can
be brachiated, i.e., having a main fluid supply line and plurality
of branch fluid supply lines in communication with the main line.
Thus, residential, commercial, institutional and industrial water
lines, and other fluid lines to include liquid antifreeze piping
systems, liquid chemical piping systems in a manufacturing or
delivery setting, and so forth, can be of concern. In general, the
invention can employ pressure decay and/or flow properties to
ascertain whether or not a leak is present, and valve control to
address a leak found to be present.
The apparatus of the invention includes control logic. Any suitable
configuration for the control logic can be employed. This may
include employment of a mechanical, electro-mechanical, or
electronic circuit device, and combination of such devices.
Preferably, the control logic includes electronic circuitry. In
communication with the control logic are included at least one of a
flow detector and a pressure detector; and a control valve.
Advantageously, the control logic may be programmed, monitored,
and/or controlled by a remotely positioned unit, for example, a
hand-held, portable, remote control unit in radio communication
with the control logic.
The flow detector can detect flow, typically to a fine degree, for
example, as little as 0.2 gallons per minute (gpm) flow of water or
less in a residential water piping system. The flow detector can be
of any suitable configuration, to include a flow switch or a flow
meter, which are well known in the art. Preferably the flow
detector is a piston/by-pass type flow meter. The flow detector can
be considered to be a user demand detector.
The pressure detector can detect loss of pressure in a piping
system that has pressurized fluid inside, generally by decay of
pressure, typically to a fine degree, for example, about from fifty
to two pounds per square inch gauge (psig) per minute in a
residential water piping system. A low threshold pressure, say, a
15-psig pressure or below in a residential water piping system that
normally operates under a 55-psig to 100-psig pressure, may be a
property that is detected to indicate loss of pressure.
Any suitable communication between the user demand and pressure
detectors and the control logic can be employed. Mechanical,
electrical and radio communication may be employed. Advantageously,
electrical communication is employed.
Beneficially both flow and pressure detectors are present.
Also, the apparatus has one or more of (1) the flow detector and
the pressure detector being both present, with each of the flow and
pressure detectors present as a single unit; (2) the control logic,
the at least one of a flow detector and a pressure detector, and
the control valve being in close proximity to one another; and (3)
the control valve having a baseline condition of being shut off. As
to the first feature, this has advantages of providing simplicity
and efficiency while still being highly effective in detecting and
controlling leaks, even in a brachiated system. As to the second
feature, this consolidation has advantages of simplicity, economy,
ease of installation and operation, and neatness, and such
consolidation can be effected by providing a relatively small
housing and mounting the components inside. As to the third
feature, this has advantages of security, especially in situations
where there is an electrical power supply outage, and
efficiency.
Numerous other features can be provided.
With respect to the drawings, FIGS. 1 and 2 depict exemplary
embodiments of the invention, which may be considered to be those
such as initially set forth in the parent. Such a disclosure can be
read, furthermore, in light of and be applied to the present
continuing disclosure. FIGS. 3-8 depict further exemplary
embodiments of and disclosure for the invention, and such matter
can be read in light of and be applied not only to the present
continuing disclosure but also to the disclosure from the
parent.
Thus, the embodiments of FIGS. 1 and 2 can be made and used as set
forth in the parent, and they can include leak detection system 100
of FIG. 1, which advantageously may be installed in a residence to
detect and limit damage from leaks from the water piping system of
the residence, which may be brachiated. And so, the system 100 can
include the following enumerated features:
TABLE-US-00001 Number Comment 102 First piping joint, attaches to
main water supply. 104 Second piping joint, attaches to residence
piping. 106 First manual valve between joints 102, 104, normally
closed in operation; can be opened for by-pass mode, for instance,
to facilitate maintenance or repairs, where water flows through the
joint 102, through the valve 106, and then out the joint 104 only.
108 Second manual valve, on a test line connected to the first
joint 102, normally open during operation, but can be closed for
by-pass mode such as for service. 110 Third manual valve, on the
test line connected to the second joint 104, normally open during
operation, but can be closed for by-pass mode such as for service.
112 Disconnect unions, on the test line and distal to the valves
108, 110, which, for example, in by-pass mode, can be loosened to
release the bottom portion of the system 100 for maintenance,
repair, or replacement. 114 Shutoff valve, may be in a baseline
open or closed configuration, through which water can flow from the
valve 108 to the valve 110 during normal operation. 116 User demand
detector, for example, a flow switch, can be preset to detect
minimal water flow, say, 0.2 gpm; and through which water can flow
from the valve 108 and valve 110 when open to the valve 110
normally. 118 Control box, contains control logic. 120 Electrical
power supply cord, communicates power to run the system 100, for
example, by plugging into a standard 120-V AC electrical outlet.
122 Electrical wires between the detector 116 and control logic of
control box 118, communicate user demand, for instance, for timing
by the control logic, which logic, for example, in a baseline open
system can cause closure of the valve 114 if the period of user
demand exceeds a set maximum time period, stopping water flow in
the piping system with which the system 100 is mounted; or which
logic, for example, can initiate and control a leakage test, and so
forth. 124 Electrical wires between the shut-off valve 114 and
control logic of the box 118, carry signals from the control logic
to close or open the valve 114. 126 User demand set dial, can be
set, for example, from a 1-minute to a 99-minute setting, to
establish a maximum user demand time period. 128 Fault indicator
light, for example, a light-emitting diode (LED), can be
illuminated through signals from the control logic whenever the
maximum user demand time period is exceeded to indicate why the
system 100 is shut down. 130 Pressure detector, for example, a
pressure switch, in electrical communication with control logic in
the box 118 through a set of wires between the detector 130 and the
control logic, can be monitored in a pressure decay test initiated
by the control logic, for example, every few hours or minutes and
under conditions of no user demand as checked through the detector
116. 131 Electrical wires between the pressure detector 130 and
control logic of the box 118, carry signals to communicate pressure
condition. 132 Pressure decay test time dial, can be preset, for
example, from a 1-second to a 99-second interval, to establish
duration of the pressure decay test period. 134 Leak-detected
indicator light, for example, an LED, lights up when the system 100
has detected a leak and accordingly has shut down. 136 System reset
button, can be pressed to restart the system 100 after shut down,
which, for example, in a baseline open configuration opens the
valve 114, etc. 138 Power-on indicator light, for example, an LED,
lights lights up when power is supplied to the system 100 as by way
of the cord 120. 140 Demand-testing indicator light, for example,
an LED, lights up when a user demand test is being performed. 142
Leak-testing indicator light, for example, an LED, lights up during
performance of pressure-decay tests.
In the system 100 with the baseline open shut-off valve 114
configuration, the flow switch 116 is employed to determine whether
user demand is present. The switch 116 can be set to any suitable
flow rate, for example, the 0.2-gpm flow rate noted above. Whenever
there is user demand, the control logic keeps track of the how long
that demand is present. If the period of user demand exceeds a
predetermined maximum user demand time, for example, as set by the
dial 126, the control logic communicates a signal to the normally
open shut-off valve 114 to close, stopping water flow through the
system 100 as well as the piping system with which it is mounted.
Also in that system 100, the control logic initiates leakage tests
according to a preset leakage test frequency, for example, every
few hours in a residential setting, by first checking the detector
116 for flow, and, if there is flow detected, the test is delayed
until there is no user demand detected. If no user demand is
detected, the leakage test is begun. The control logic causes
closure of the shut-off valve 114, stopping water flow into the
system 100 and the residential water piping, and the logic then
begins to monitor the pressure detector 130 for its predetermined
time, i.e., for the pressure decay test time, for example, for a
30-second period in the residential setting as set by the dial 132.
The detector 130 detects if the pressure in the piping system drops
below a predetermined acceptable pressure, for example, a 15-psig
value in the residential setting. If the pressure has dropped below
the acceptable pressure, then the control logic initiates a test to
determine if there is user demand such as caused by a user turning
on a faucet that commenced after the beginning of the pressure
decay test and before ascertaining whether or not the minimum
acceptable pressure has been breached. The control logic performs
this test for user demand by first opening the shut-off valve 114,
which had been closed for the pressure decay test, and then
checking the flow detector 116 to determine if the minimum user
flow rate has been reached. In some applications, fluctuations in
flow rate may exist for a brief period after reopening of the valve
114. The control logic may account for these fluctuations by
delaying for a short time, for example, about half a second, before
checking the flow detector 116 for user demand, or the control
logic may check that the detector 116 has detected a minimal user
flow rate continuously for a short period, for example about half a
second, before determining that user demand is present. If the test
for user demand performed during a leakage test shows that no user
demand is present, then there is a leak in the piping system, and
the control logic sends a signal to the shut-off valve 114 to
close, stopping water flow through the system 100 and hence the
piping system with which it is mounted. On the other hand, if the
test for user demand performed during a leakage test shows that
indeed there is user demand present, the control logic keeps the
valve 114 open and waits until no user demand is detected, at which
time the leakage test is restarted.
The exemplary leak detection method 200 of FIG. 2 can include the
following enumerated features and steps:
TABLE-US-00002 Number Comment 202 Leakage test, employs frequency
timing, for example, with a timer, to determine when to start a
test 202. 204 Determination of the presence of user demand. 206
Demand timing, for example, with a timer, starts when user demand
204 is detected, and keeps track of how long user demand is
present. 208 Maximum user demand time, compared to current user
demand as timed by the demand timing 206. 210 Exceeding of maximum
demand, can shut down system as by closing a shut-off valve if time
208 exceeded. 212 Determining if user demand present, carried out
if the time 208 is not exceeded. 214 Leakage test timing, for
example with a timer, started if no user demand; if user demand is
present, determine whether the maximum demand time 208 has been
exceeded and whether user demand 212 is present until either
maximum demand is exceeded 210 or there is no longer user demand.
216 Pressure decay test, timing, for example, with a timer, started
when no user demand is present or detected user demand stopped, and
detector checks for pressure drop or decay in the piping system.
218 User demand check if pressure decay detected. 220 Leak detected
if no user demand 218 present; if user demand detected the test 216
is halted, user demand timing 206 is started, and the method
proceeds as above until either no user demand is present or the
maximum user demand time has is exceeded 210. 222 Expiration of
decay test time, checked if no pressure decay is detected; if the
time 222 has expired, then the pressure decay test is complete, and
no leak has been found; if the pressure decay test time 222 has not
expired, then checking for pressure decay 216 is continued, and
checking to determine if the test time 222 has expired continues
until either pressure decay has been detected or the test time 222
has expired.
Further, embodiments as depicted in FIGS. 3-8 are provided.
Such embodiments can include apparatus 100' of FIGS. 3-5. The
apparatus 100', which has fluid by-pass line 100B and fluid test
circuit 100C, can include main enclosure (housing) 101' made of any
suitable material, for example, aluminum or stainless steel sheet
metal, and can be of a relatively small size, for example, about a
16-inch height by a 12-inch width by a 4-inch or so depth. The
housing 101' can have access openings 101A, for example, in its
front face 101F, say, for access or visibility to valves and/or a
control panel. The face 101F may have indicia thereon such as
provided by silk-screening, engraving, and so forth. To the inside
of the housing 101' can be mounted a number of retaining fasteners
such as lower secure retaining clip 101L and two upper spring
retaining clips 101U, each of which have employ threaded retaining
clip stand off 101X and retaining clip lock nut 101Y to fasten
other components of the apparatus 100' such as piping, for example,
the lower clip 101L holding onto a 3/4-inch diameter by 5 5/16-inch
length copper tube nipple 101LN, which is attached on its
water-entry end to a 3/4-inch diameter copper tube elbow 101E and
on its water-exit end to a 3/4-inch National pipe thread male
(NPTM) threaded tube adapter 101TF made of iron, steel, aluminum,
copper, plastic, ceramic or the like; one upper clip 101U holding
onto a 3/4-inch diameter by 25/8-inch length copper tube nipple
101UN, which is attached to a 3/4-inch diameter copper tube tee
101UT, which embraces first piping joint 102' that attaches to main
water supply and into which water can flow; the other upper clip
101U holding onto another 3/4-inch diameter by 25/8-inch length
copper tube nipple 101UN', which is attached to another 3/4-inch
diameter copper tube tee 101UT', which embraces second piping joint
104' that attaches and can deliver water to the residence piping
system. Other pipe conduit sections can include two 3/4-inch
diameter by 13/8-inch copper tube nipples 103, 103'; two 3/4-inch
diameter by 15/8-inch length copper tube nipples 103A, 103A'; a
3/4-inch diameter by 31/4-inch length copper tube nipple 103B; a
3/4-inch through diameter to 1/2-inch side diameter copper reducing
tee 103T; and two 3/4-inch NPTM by 3/4-inch male threaded tube
adapters 103TM, 103TM' made of iron, steel, aluminum, copper,
plastic, ceramic or the like. Advantageously, one or more manual
control valves are employed, but these otherwise may be automatic
or opened or closed with the assistance of motive power such as
electromotive power, or otherwise may be eliminated although that
is not desirable, and such valves may be first, second and third
manual valves 106', 108', 110', each of which, for example, can be
a 3/4-inch diameter tube block and iso ball valve, which have
handles 106H, 108H, 110H and retaining bolts 106R, 108R, 110R,
respectively. As in the previous exemplary embodiment, the first
manual valve 106' is mounted between the joints 102', 104' and is
normally closed in operation; it can be opened for by-pass mode,
for instance, to facilitate maintenance or repairs, where water
flows through the joint 102', through the valve 106', and then out
the valve 104' only. The second and third manual valves 108', 110'
are mounted on test line sections connected to the first and second
joints 102', 104', respectively; and these are normally open during
operation, but can be closed for by-pass mode. Disconnect unions,
112' 113' are on the test line sections and distal to the valves
108', 110', respectively, which, as also in the previous exemplary
embodiment, in by-pass mode can be loosened to release the lower
portion of the system 100' for maintenance, repair, or replacement.
The union 112' can be, for example, a 3/4-inch diameter by 3/4-inch
diameter NPTM adapter union made of iron, steel, aluminum, copper,
plastic, ceramic or the like; and the union 113' can be, for
example, a 3/4-inch diameter tube union made of iron, steel,
aluminum, copper, plastic, ceramic or the like. Such components as
well as others can be connected with further components and
sections by soldering or threading, or in any other suitable
manner, as appropriate.
The apparatus 100' also includes shut-off valve 114', for example,
a Parker (Skinner Valve Div.) solenoid valve, model No.
7321BBN53NOONOL11P3-3/4-inch orifice, 2-150 psig, 120-V AC, 60-Hz,
Code 3004D, 10-watt valve. Although a shut-off valve, of which the
valve 114' is representative, may be in a baseline open or closed
configuration, it is preferably in the baseline closed position by
which it normally resorts to the closed position to stop all water
flow through the apparatus 100' unless the control logic directs
otherwise, conveniently through electric communication wiring 114C,
although radio or other manner of communication may be employed; in
its open position, of course, water can flow from the valve 108'
through the valve 114' to the valve 110' and out the second joint
104' to the piping and its branch lines, which the apparatus 100'
can serve.
User demand detector 116', for example, an FS-1 GEMS FS-500/170231
flow switch, 3/4-inch diameter National pipe thread female (NPTF)
unit of polypropylene construction, set to about 0.25 gpm (T.H.)
can detect minimal water flow. The detector 116' can be in
communication with the control logic conveniently through electric
wiring 116C, although radio of other manner of communication may be
employed. Water can flow through the detector 116' from the valve
108' to the valve 110' and so forth.
Pressure detector 117' detects loss of pressure. It can be, for
example, a GEMS 206056 pressure switch, 7-25 pounds per square inch
G2 PS32-20-4MNB-B-SP-FX20PSIF SPST/NC spade, 1/4-inch NPTM, factory
set at a 20-psig falling value, which is connected to the water
test line through adapter 117A, for example, a 1/2-inch diameter
tube fitting to 1/4-inch diameter NPTF adapter, and in
communication with the control logic conveniently through electric
wiring 117C, although radio of other manner of communication may be
employed. Among other things, the detector 117' can be monitored in
a pressure decay test initiated by the control logic, for example,
every few hours and under conditions of no user demand as checked
through the detector 116'.
Power for the apparatus 100' can be supplied through electrical
power supply cord 120'. The cord 120', which can be secured to the
housing 101' with power cord retainer 120R so that it does not get
pulled away from the control box 118' so easily, communicates
power, for example, by plugging it into a standard 120-V AC
electrical outlet; or it may be permanently connected.
Control panel or box 121' can contain the control logic. Compare,
FIG. 5 (solid state control wiring diagram). Cover 121C may be
provided with the control box 121'. Various indicator light and
control features can be provided on front face 121F of the control
panel 121'. For instance, such features can be provided as
follows:
TABLE-US-00003 Number Comment 126' User demand set dial, for
example, an adjustable one million ohm potentiometer, is set for
the maximum allowed time for continuous flow before the valve 114'
returns to its closed baseline position, for example, set from an
about 1-minute to 100-minute setting, to establish the maximum user
demand time period. This may be considered a "flow guard knob."
128' Fault indicator light, for example, a light-emitting diode
(LED) or other pilot light, such as of a red color, can be
illuminated through signals from the control logic whenever a
demand flow has exceeded the preset value or when a low rate count
exceeds the set value to indicate why the apparatus 100' has
stopped flow of water. It may be considered a "flow fault lamp."
134' Leak-detected indicator light, for example, an LED or other
PL, such as the red light 128', lights up when a leak test has
failed or when a low rate count exceeds the set value to indicate
why the apparatus 100' has stopped flow of water. This may be
considered a "leak fault lamp." 136' Reset button, beneficially a
Form C push button, can be pressed to restart the apparatus 100',
say, after shut down. Consider this a "system reset button." 138'
Power-on indicator light, for example, an LED or other PL such as
the red lights 128', 134', lights up when the main control power is
on. This may be considered a "power-on lamp." 140' Demand indicator
light, for example, an LED or other PL such as a yellow control
pilot light, lights up when water is flowing. This may be
considered a "flow guard lamp." 142' Leak-testing indicator light,
for example, an LED or other PL such as the yellow light 140',
lights up while a leak test is being conducted. This may be
considered a "leak guard lamp."
Also, indicia may be provided on the front face 121F.
Accordingly, the features on the control panel face 121F of the
control panel 121' of the apparatus 100' can differ from those
found on the control panel 118 of the system 100. For example, a
pressure decay test time dial such as the dial 132 in the system
100 may be absent; it may be provided elsewhere, or its function
may be provided as a built-in, non-controllable or a programmable
or communicatable function, say, by remote control.
As shown in FIG. 6, the system or apparatus 100, 100', especially
the apparatus 100', may be provided with remote control such as
from a wireless unit, for example, hand-held, battery-powered
radio-transmitter/receiver unit 150' (RC-1), and various functions
may be provided with the unit 150'. Wireless control may otherwise
or in addition to radio be provided by other electromagnetic
radiation (EMR) such as infrared light, visible light, ultraviolet
light or other EMR; sound or other physical vibration or impulse;
and so forth. Radio communication may be amplitude modulated (AM),
frequency modulated (FM), digital pulse modulated (DM), etc. FM is
preferred. Push button switches, for example, "A," "B," "C," and
"D," set to different frequencies, may provide for remotely
activating these functions:
TABLE-US-00004 Button Comment Button Comment "A" System reset. "C"
Vacation. "B" By-pass. "D" Access/exit program.
Installation and start up of the system/apparatus 100, 100' can be
simple and quick, especially when carried out by a licensed
plumber. All soldered joints must have high integrity. The unit
100, 100' is beneficially installed in the main fluid supply line,
for example, a solitary standard main water supply line at the
point of entry into a building structure or other boundary
delineating the remainder of the system. There should be no
backfeed of fluid into the plumbing system beyond the unit 100,
100' by another supply. Advantageously, the unit 100, 100' is
installed in systems having 3/4-inch copper piping; otherwise,
other fittings and/or adapters are provided. Installation, for
example, of the apparatus 1001 can be carried out as follows: 1.
The water supply is turned off at the main incoming valve. Water is
drained from the piping system until all flow has stopped. 2.
Installation generally requires 121/2 inches in width and 161/2
inches in height. A location is selected in which installation is
in an upright position. If the existing piping arrangement is
vertically oriented, the necessary fittings are installed to
achieve the desired alignment. Use of the fewest fittings is
recommended. Mounting can be on a wall such as with pipe hangers
and stand-offs, or be installation can be directly in a horizontal
pipe line. 3. Unions or flex fittings are not desired for
installation. 4. Nine inches of the existing pipe is removed, or,
if new lines have been installed, connections are prepared as
required. The unit 100' is inserted into the piping, or new piping
is set into place. 5. The manual valves 106', 108', 110' are
opened. This can eliminate damage caused when solder joints are
made. 6. The valve handles 106H, 108H, 110H are removed. 7. The
housing 101' is gently pulled out and swung down, as it is attached
at its lower end and will remain in place. Pressure clips 101U
retain the position at the top. The inside components are
protected, and solder joints are made, insuring that alignment is
correct. 8. The housing 101' is placed back into position, and the
valve handles 106H, 108H, 110H are replaced.
The unit 101' can now be tested for leaks and prepared for service.
Start-up and testing of the apparatus 100', for example, can be
carried out as follows:
1. Regarding piping and water supply system, the main water supply
valve is slowly opened, and the plumbing system is allowed to fill.
After several moments waiting all taps are then closed, starting
from the nearest to the most distant. The objective is to remove as
much air from the system as possible. Small amounts of air will be
trapped but will be absorbed over time. The installation is
inspected for leaks, and corrections are made as necessary. The
by-pass valve 108' is closed, keeping the test line valves 106',
110' open. All handles 106H, 108H, 110H should be in the vertical
position.
2. Regarding system power, the power cord 120' is plugged into a
120-V AC outlet. The red power-on lamp 138' lights up.
3. Regarding an initial flow check, the flow guard knob 126' is
turned to the maximum position of "10," i.e., a 100-minute setting.
Any tap in the water piping system is opened, and the flow is
observed. Water should begin to flow as usual, then slow down
slightly, and then go back to full flow. This verifies that the
unit 100' is sensitive to a water demand request. The yellow flow
guard lamp 140' should turn on within two seconds and remain on
until the tap is closed. The selected tap is then turned off, and
the lamp 140' should go out.
4. Regarding an excess flow check, the flow guard knob 126' is
turned to its minimum position, i.e., a 1-minute value. A tap is
opened. The flow guard lamp 140' should go on. The water is allowed
to continue to run, and the time is observed. In about one minute,
the water should shut off automatically by work of the apparatus
100'; the lamp 140' will go out, and the red flow fault lamp 128'
will come on.
5. Regarding flow guard set up, the flow guard knob 126' is turned
to the desired position. A 20-minute to 25-minute setting is
usually plenty for typical applications. It is recommended that
this setting be adjusted to the minimum time feasible, thus, among
other beneficial things, conserving water resources.
Further technical data for the apparatus 100' can embrace the
following:
1. User inputs associated with the control logic can include the
following inputs controllable from the panel front 121F: system
reset button 136' (PB-1); and flow guard knob 126', a variable
resistor type with control in minutes (SP-1). The wireless remote
150' (RC-1) also provides for user input.
2. User monitoring outputs located on the panel front 121F and
associated with the control logic can include the following:
power-on lamp 138' (PL-1); flow guard lamp 140' (PL-2); flow fault
lamp 128' (PL-3); leak guard lamp 142' (PL-4); and leak fault lamp
134' (PL-5). Also, user monitoring outputs may be located on the
remote 150'.
3. Standard inputs with respect to terminal strip wiring associated
with the control box 121' and control logic can include the
following: for power, 120-V AC, from the cord 120' (TB-7), with
black wire hot, neutral wire white, and green wire ground; for the
flow switch 116' (TB-3) with normally open (N.O.) contact, which
closes contact at approximately 0.21 gpm on increasing flow; and
for the pressure switch 117' (TB-4) with normally closed (N.C.)
contact (TB-4), which opens contacts at approximately a 30-psig
value on increasing pressure.
4. Standard output with respect to terminal strip wiring associated
with the control box 121' and control logic can include that to the
shut-off control valve 114' (CV-1) (TB-6), 120-V AC 60-Hz, normally
closed, full port.
5. Auxiliary inputs with respect to optional terminal strip wiring
associated with the control box 121' and control logic may include
the following: an external reset switch (TB-5), which allows the
user to reset a fault condition from a hardwired switch away from
the control panel, for example, in a kitchen, laundry room,
bathroom, garage, by an outdoor faucet or water heater, and so
forth, and which has normally open contact with multiple switches
able to be wired in parallel; and a flow guard override switch
(TB-2), which would indicate that a long-demand item needs water
such as for a water-sprinkler system, a water softener, and so
forth, N.O. contact input, usually from a relay or flow switch.
6. Auxiliary outputs with respect to optional terminal strip wiring
associated with the control box 121' and control logic may include
the following: fault lamp (TB-1), a security system link (N.O.),
closed on fault, which requires power be supplied to the unit 100'
for operation; power lamp (TB-8), 5-V DC, which is for service; and
a ground for shielding.
7. Non-stored configuration settings with respect to terminal strip
wiring associated with the control box 121' and control logic can
include that from a flow guard timer (TM-3) set by the flow guard
knob 126', which is the maximum continuous time that water can run,
except when a flow guard override (TB-2) signal has been received.
This is a user-adjustable factor, and about twenty minutes is
recommended.
8. Stored configuration settings, electrically erasable permanent
read only memory (EEPROM), with respect to terminal strip wiring,
which may be optional, associated with the control box 121' and
control logic, can include the following: a leak test cycle timer
(TM-1), which times intervals between leak tests, set typically for
twenty minutes, and which can be programmably adjustable, say, from
the remote 150' to a 1-minute to 100-minute value; a leak test
decay timer (TM-2), which times the duration of the leak test, set
typically for five minutes, and which can be programmably
adjustable, say, from the remote 150' to a 1-minute to 100-minute
value; a flow guard override timer (TM-4), which is an auxiliary
input that times the maximum duration water can run when the flow
guard timer (TM-3) is being overridden (TM-2), set typically for
two hours, and which can be programmably adjustable, say, from the
remote 150' to a 1-hour to 10-hour value; a surge flow timer
(TM-5), which times the minimum time allowed to establish a flow
signal, i.e., the time allowed to establish a verified flow where a
flow signal pulse from the flow switch 116' is expected when the
piping system repressurizes and for which the flow switch 116'
remains activated for the adjustable time period in order for a
logical one-flow signal to be generated, set typically for two
seconds, and which can be programmably adjustable, say, from the
remote 150' to a 1-second to 10-second value; a surge window timer
(TM-6), which controls the time allowed for flow verification,
i.e., the maximum time allowed for verified flow signal to be
established and begin the next programmable step, set typically for
ten seconds, and which can be programmably adjustable, say, from
the remote 150' to a 1-second to 10-second value; a low flow rate
timer (TM-8), which determines possible low flow such as from
drip-watering of plants or making ice in a freezer versus a leak,
i.e., the time window at the beginning of a leak test when a low
pressure condition is considered a "low flow" instead of a leak,
set typically at three or eight seconds, and which can be
programmably adjustable, say, from the remote 150' to a 1-second to
20-second value; and a configuration timer (TM-9), which is for
limiting the time allotted to complete programming of the apparatus
100', say, through the remote control 150', although it can be
beneficially factory preset to a default duration value, e.g., a
20-minute value.
9. Limits associated with the control logic can include the
following: a leak failure limit (RG-1), which is the number of leak
test failures that it takes for the apparatus 100' to go to a leak
fault status indicated by the lamp 134' (PL-5), set typically to a
default value of three, and which can be programmably adjustable,
say, from the remote 150' to a 1-count to 10-count value; and a low
flow failure limit (RG-2), which is the number of low flow failures
that it takes for the apparatus 100' to go to a flow fault status
indicated by the lamp 128' (PL-3), set typically to a default value
of three, and which can be programmably adjustable, say, from the
remote 150' to a 1-count to 10-count value.
10. Further features can be provided. For example, a last known
state (normal, leak fault, flow fault, and so forth) hard program
can be provided, which, for example, upon reset or restarting of
the apparatus 100', returns the control logic to the last step at
which it had been functioning previously. The state is updated in
EEPROM when a fault occurs or is cleared.
Some internal variables that relate to Current State of the
apparatus 100', for example, leak fault, flow fault, normal
operation, and so forth, can include the following:
1. Leak failure count, which is the number of leak tests failed due
to a possible leak, but not within the low flow leak time, since
the last leak test had been passed, is the maximum number that the
apparatus 100' is allowed to fail, and may be identified, "Leak
Test Failures"; and
2. Low flow failure count, which is the number of leak tests failed
within the low flow leak time since the last leak test had been
passed, is the maximum number that the apparatus 100' is allowed to
fail, and may be identified, "Low Flow Failures."
A sequence of operation with the apparatus 100' generally occurs as
follows:
1. Power up, i.e. electrical power is supplied, and the apparatus
100' begins or continues its work. It includes the following
indicators, conditions and contingencies: Power On, which indicates
that electrical power is being supplied, for which the red power-on
lamp 138' (PL-1) lights; Leak Guard Fault, for which the red leak
fault lamp 134' (PL-5) lights; Flow Guard Fault, for which the red
flow fault lamp 128' (PL-3) lights; and Low Flow Fault, for which
the red lamps 128' (PL-3) and 134' (PL-5) light. All values are set
to the default values, which are for the timers (TM-1 through TM-9)
to their configured values; for the leak failure count (RG-1) to a
value of zero; and for the low failure count (RG-2) to a value of
zero.
2. Start, i.e., the leak test timer (TM-1) is started to perform
the initial or next leak test.
3. The control logic puts the unit 100' in Stand-by Mode.
With respect to stand-by mode, the following happens: 1. The unit
100' goes to re-pressure mode (and returns to this point from
certain subsequent steps). 2. The water valve 114' is turned off,
and the following occurs: if flow is detected while timing, go to
Demand Flow Mode; if low pressure is detected, go to Re-pressure
Mode; if the reset button 136' (or equivalent by remote) is pushed,
go to Leak Test Mode; and when the leak test timer (TM-1) reaches
its upper limit, go to Leak Test Mode.
With respect to the Re-pressure Mode, the following happens: 1. The
water valve 114' is turned on (opened). 2. The surge window timer
(TM-6) is started, and the following occurs: if flow starts, the
surge timer (TM-5) is started; if flow continues until the surge
timer (TM-5) expires, go to Demand Flow Mode; if demand override
occurs through operation of the low flow rate timer (TM-8), go to
Demand Override Mode; and when the surge window timer (TM-5)
reaches its upper count, return to calling mode, i.e., Demand Flow
Mode, Leak Test Mode or Stand-by Mode.
With respect to the Demand Flow Mode, the following happens: 1. The
flow guard lamp 140' (PL-2) is turned on. 2. The shut-off control
valve 114' (CV-2) is opened. 3. The demand time timer (TM-3) is
started, and when flow is detected the demand time timer counts
down demand time. 4. If any reset button 136' or equivalent by
remote (PB-1, PB-A or wired remote reset PB-R) is activated, the
demand timer (TM-3) will reset. 5. If the "B" button (PB-B) on the
wireless remote 150' is activated, the following occurs: the water
control valve 114' (CV-1) is kept open; a wait ensues until water
stops flowing (FS-1); then the flow guard lamp 140' (PL-2) turns
off; the leak test timer (TM-1) is restarted; and the unit 100'
returns to Stand-by Mode.
With respect to the Demand Override Mode, the following happens: 1.
When demand override input is detected, the valve 114' (CV-1) is
opened. 2. The flow guard lamp 140' (PL-2) is turned on. 3. The
override timer (TM-7) is started, and the following occurs: if any
reset button (PB-1, PB-A, PB-R) is activated, the override timer
(TM-7) will be reset; if the demand override input (TB-2) stays
detected until the override timer (TM-7) expires, then the
following occurs: the valve 114' (CV-1) is turned off; the red flow
fault lamp 128' (PL-3) lights; the flow guard lamp 140' (PL-2)
turns off; the Current State is set to Flow Fault; and the unit
100' waits for Reset input. 4. If the demand override input (TB-2)
opens before the override timer (TM-7) expires, the following
occurs: the flow guard lamp 140 (PL-2) turns off; the leak test
timer (TM-1) starts; and the unit 100' returns to Stand-by
Mode.
With respect to the Leak Test Mode, the following happens: 1. The
unit 100' returns to the Re-pressure Mode, and the following
occurs: the leak guard lamp 142' (PL-4) turns on; and the valve
114' (CV-1) is turned off, closing the water inlet and trapping the
water under pressure in the pressurized piping system, noting
further that pressure related to the actuated valve may be
influenced by head pressure, and if the head pressure were to fall,
the pressure after the valve will follow, but if the head pressure
rises, the trapped pressure after the valve will stay the same. 2.
The leak decay timer (TM-2) is started. 3. The low flow leak timer
(TM-8) is started. If the leak decay timer (TM-2) expires and the
pressure switch 117' (PS-1) never indicated low pressure in this
time, then the following occurs: the valve 114' (CV-1) is turned on
(opened); the leak guard lamp 142' (PL-4) is turned off; the leak
failure count (RG-1) is set to zero; the leak test timer (TM-1) is
reset; and the unit 100' returns to Stand-by Mode. 4. If there is a
pressure drop, the unit 100' does the following:
TABLE-US-00005 turns on (opens) the valve 114'' (CV-1); if flow
(FS-1) is indicated for longer than the surge time (TM-5) and
within the surge window time (TM-6), then the following occurs: the
leak guard lamp 142' (PL-4) turns off; the leak test timer (TM-1)
is reset; and the unit 100' goes to Demand Flow Mode; if flow is
not indicated for longer than the surge time (TM-5) within the
surge window time (TM-6), then the following occurs: if the low
flow leak timer (TM-8) had expired when the pressure dropped, then
the following occurs: the leak failure count (RG-1) is increased by
one; if the leak failure count (RG-1) reaches its limit, then the
following occurs: the valve 114' (CV-1) is turned off (closed); the
red leak fault lamp 134' (PL-5) lights; the leak guard light 142'
(PL-4) is turned off; the Current State is set to leak fault; and
the unit 100' waits for Reset input; if the leak failure count
(RG-1) has not reached its limit, then the following occurs: the
leak guard lamp 142' (PL-4) is turned off; the leak test timer
(TM-1) is reset; and the unit 100' goes to Stand-by Mode; if the
low flow leak timer (TM-8) had not expired when the pressure
dropped, then the low flow failure count (RG-2) is increased by
one, and the following occurs: if the low flow failure count (RG-2)
has reached the low flow failure limit, the following occurs: the
valve 114' (CV-1) is turned off (closed); the red flow fault lamp
128' (PL-3) is turned on; the red leak fault lamp 134' (PL-5) is
turned on; the leak guard lamp 142' (PL-4) is turned on; the
Current State is set to flow fault; and the unit 100' waits for
Reset input; if the low flow failure count (RG-2) has not reached
the low flow failure limit, the following occurs: the leak guard
lamp 142' (PL-4) is turned off; the leak test timer (TM-1) is
reset; and the unit 100' goes into Stand-by Mode.
Further regarding the remote control unit 150' (RC-1) and its
response with the apparatus 100', the following is noted: 1. Push
button "A" (PB-A) is a system reset function. It elicits response
by the panel control box (PCB) 121' of resetting the system, the
same as pressing the reset button 136' on front panel 121F. If
pushed while in the Stand-by Mode, the apparatus 100' will perform
a leak test. A failure of one count in this operation will shut off
the water through the valve 114' (CV-1). 2. Push button "B" (PB-B)
is a by-pass function. It elicits response through the PCB 121' of
a by-pass such that, if pressed while in the Demand Mode, i.e.,
water is flowing by user demand, the valve 114' (CV-1) is kept open
for as long as water continues flowing, but as soon as the water
stops flowing such as by shutting all taps any effects of pressing
the button are canceled. 3. Push button "C" (PB-3) is a "vacation"
function. It elicits the response through the PCB 121' of forcing
the valve 114' (CV-1) to close until the apparatus 100' is reset;
both the flow guard lamp 140' (PL-2) and the leak guard lamp 142'
(PL-4) are turned on. 4. Push button "D" (PB-4) is an access/exit
to programming function. It elicits a programming response through
the PCB 121'. For example, if pressed three times within six
seconds while in any mode except for Power Up or any of the Fault
Modes, an operator can enter Configuration Mode in which
programming of the apparatus 101' can be carried out. Pushing this
button while in the Configuration Mode will exit the operation, and
the unit 100' will go back to the Stand-by Mode.
With respect to the Configuration Mode, the following is noted: 1.
Configuration Mode is entered by pressing the "D" button (PB-4) on
the remote 150' three times within six seconds in any mode except
Power Up or a Fault Mode. The valve 114' (CV-1) is opened and
remains open for as long as the apparatus 100' remains in
Configuration Mode. The 20-second configuration timer (TM-9) is
started. If this time expires while in Configuration Mode,
Configuration Mode is exited. While in the Configuration Mode, some
of the lamps on the front panel 121F will be continuously blinking
to indicate which configuration setting is being altered. Pressing
the button "A" (PB-A) on the remote 150' advances to the next
configuration option. Pressing the reset button such as the button
136' stores a new value into the currently selected configuration
option, based on the current value of the front panel
potentiometer, or in the case of the default options, stores
default values into all user-configurable settings. Indicator
lights that were blinking then light uninterruptedly for two
seconds to indicate that a value has been stored for the selected
function. The configuration mode can be exited by pressing the
button "D" (PB-D) on the remote 150'. When Configuration Mode has
been exited, Stand-by Mode is entered. 2. Programming with the
remote 150' in Configuration Mode may be carried out in sight of
the control face 121F. 3. Programming with the remote unit 150' can
be carried out. The noted remote button descriptions are as
follows: Button "A" (PB-A) activates reset and hence provides a
manual leak test, and acts as a configuration stepper, i.e., it
brings up the next function on which the user may operate and
program; Button "B" (PB-B) activates the Demand Flow Override Mode;
Button "C" (PB-C), the "vacation" button, shuts down flow through
the valve 114' (CV-1) and lights up the flow and leak guard lamps
140', 142'; and Button "D" (PB-D) activates programming. For
programming the apparatus 100' initially, which is advantageously
carried out at its manufacturing facility, the following steps can
be carried out: Select microprocessor board as a panel control
board (PCB), which will have hardware suitable for the control
logic of the unit 100'; record its serial number in a test records
file; connect power cord and insert PCB into a test stand
accommodating it, and apply power to the PCB in the test stand.
Load program; connect cable to interpreter and PCB. Select program
icon on desk top, control program loads; then check, "CONFIG."
Connect cable directly to PCB serial port. Select "CONFIG" icon on
desk top, from which a window for configuration appears; select,
"COM PORT 4"; press CONNECT; press RETRIEVE VALUES, and then Push
button "D" (PB-D) on remote 150' (RC-1) three times within six
seconds. Push button "A" (PB-A) on remote 150' one time to step to
each successive parameter, as set forth in the following table:
TABLE-US-00006 Configuration Step Flow Guard Value Lamp Light
Indication 1 - Leak test cycle time 1-100 minutes Leak Guard 2 -
Leak test decay time 1-100 minutes Leak Fault 3 - Manual override
time 1-10 hours Flow Guard 4 - Low flow rate time 1-20 seconds Flow
Fault 5 - Leak test fail count 1-10 counts Leak Gd. and Flow Gd. 6
- Low flow fail count 1-10 counts Flow Ft. and Leak Gd. 7 - Surge
flow time 1-10 seconds Flow Gd. and Flow Ft. 8 - Surge window time
1-20 seconds Flow Gd. and Leak Ft. 9 - Restore default Fixed, not
used All lamp lights on.
To exit Configuration Mode, push button "D" (PB-D) at any time
during programming. The following table relates to functions and
default settings:
TABLE-US-00007 Definition of Function Default 1 - Time after each
demand when a leak test begins 20 mins. 2 - Time allowed for a
pressure drop to indicate leak 5 mins. 3 - Time that demand timer
has no effect on fault trip 2 hours 4 - Time window for low
pressure to indicate low demand 8 secs. 5 - Number of times allowed
for a failed leak test 3 counts 6 - Number of times allowed for a
low demand 3 counts 7 - Time for a demand flow signal to be
established 2 secs. 8 - Time allowed for the demand flow signal to
verify 10 secs. 9 - Pressing the panel reset 136' restores all
default settings.
For the customer to change a value on a selected unit 100', the
following is carried out with the remote unit 150' (RC-1) while he
is or can get quickly yet conveniently positioned in view and reach
of the control box face 121F: 1. The button "D" is pushed three
times within six seconds to enter the program mode. 2. The button
"A" is pushed to select the function, one push for each successive
function, verified, for example, by the display of the appropriate
panel lamps, as above. 3. The flow guard knob 126' is adjusted to
the desired value while that function is actively engaged, and the
selected value is confirmed with a setup unit at a help desk. 4.
The new value is sent to the control logic by pushing the reset
button 136' on the control panel front 121F. The lamp(s) which
indicate(s) which function is having its value changed, as noted
above, light(s) for two seconds, indicating that change has been
made. 5. This is repeated for any other adjustable function. 6. The
Program Mode is exited by pushing the button "D" on the remote
control 150' once. The value(s) is(are) loaded, and the apparatus
100' returns to normal operation, operating under the changed
values.
Thus, generally in accordance with that set forth above, operation
of the invention, advantageously with the apparatus 100' of FIGS.
3-6, can be carried out according to the flow chart of FIG. 7. A
sample pressure decay function is shown in FIG. 8.
And so, the unit 100, 100' can monitor an entire fluid supply
system from one point. There are no remote sensors or remotely
positioned batteries (save that of the remote control unit 150') to
replace, which can otherwise be a trying experience. The unit 100,
100' can operate on standard household power and can be provided
with "fail safe" security, i.e., water can be shut off
automatically by default, for example, in the event of a power
outage, most expressly the unit 101'. If water is needed while the
power is off, the built-in by-pass valve 106, 106' can be opened
for this, and it is closed again after the power is on. The
invention conserves water, and saves the owner from the costly
problems of dripping faucets and forgotten running taps by using
its applied control logic for all normal exits as well as system
faults and failures.
Other features may be provided. For example, a screen may be
provided on the remote control 150' by which remote program steps
and functions can be displayed in an alphanumeric or character
format, thus avoiding interpretation of indicator panel lamps and
the need to program the apparatus 100' by the operator with the
remote control 150' directly in front of the display panel 121F. To
more fully facilitate this, a dial or other suitable contrivance
such as a keyboard or roller control may be provided on the remote
control unit in lieu of the dial 126'. As well, a screen may be
provided on the control box 121' that indicates in alphanumeric or
character format the values and other parameters under which the
apparatus 100' is operating. Then, too, function of the remote 150'
may be built in to the housing 101', say, with the control box
121', with or without a separate remote unit 150' being provided
with the apparatus 100'.
Accordingly, the invention, especially as embodied to include the
apparatus 100', can have the following beneficial features related
to the apparatus 100' itself: No batteries. No backup power
required. Use of 120V AC. Fail safe design. No wiring to remote or
external sensors. No remote or external sensors. Easy installation.
Compact design. Fully assembled for installation. Installation to
existing water line. Attractive enclosure and appearance. Remote(s)
150' included for consumer use. No difficult programming required
by user. The apparatus 100' can automatically do the following:
Detect the smallest drip or leak, and shut the water off. Turn off
the water if accidentally left on. Turn off the water when the user
leave the premises. Turn on the water when the user returns.
Protect the home or other building structure even when the
electrical power has failed. Automatically reset and get back to
the job after the end of a power outage.
CONCLUSION TO THE INVENTION
The present invention is thus provided. Various feature(s),
part(s), step(s), subcombination(s) and/or combination(s) can be
employed with or without reference to other feature(s), part(s),
step(s), subcombination(s) and/or combination(s) in the practice of
the invention, and numerous adaptations and modifications can be
effected within its spirit, the literal claim scope of which is
particularly pointed out as follows:
* * * * *